Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
i SAFETY i FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fume...
Page 3 - ii
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii; Refer to
iii SAFETY iii FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the ...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secouss...
Page 6 - Conformance
v SAFETY v AIR VANTAGE® 500 (AU) Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility,2004/108/EC. It w...
Page 8 - Thank You; Please Examine Carton and Equipment For Damage Immediately
vii vii Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this ma...
Page 9 - TAbLE OF CONTENTS
viii viii TAbLE OF CONTENTS Page Installation .......................................................................................................................Section A Technical Specifications .......................................................................................................
Page 11 - INSTALLATION; INPUT - DIESEL ENGINE
AIR VANTAGE® 500 (AU) A-1 INSTALLATION A-1 TECHNICAL SPECIFICATIONS - AIR VANTAGE® 500 (AU) (K32012-1) Make/Model Description Speed (RPM) Displacement Starting Capacities cu. in. (ltrs.) System 4 cylinder High Idle 1900 199(3.3) 12VDC Battery & Fuel: 25 gal. Cummins 56 HP (42kw) starter (94.6 L)...
Page 12 - SAFETY PRECAUTIONS; electrode with skin or wet clothing.
A-2 INSTALLATION AIR VANTAGE® 500 (AU) A-2 SAFETY PRECAUTIONS Only qualified personnel should install, use, or service this equipment. Do not attempt to use this equipment until youhave thoroughly read the engine manufacturer’smanual supplied with your welder. It includesi m p o r t a n t s a f e t ...
Page 13 - LIFTING
A-3 INSTALLATION AIR VANTAGE® 500 (AU) A-3 LIFTING The AIR VANTAGE® 500 (AU) lift bale should be usedto lift the machine. The Air Vantage 500 is shippedwith the lift bale retracted. Before attempting to lift theAIR VANTAGE® 500 (AU) the lift bale must be securedin a raised position. Secure the lift ...
Page 14 - OIL; FUEL CAP
ENGINE COOLANT HOT COOLANT can burn skin. •Do not remove cap if radiator is hot. ------------------------------------------------------------------------ The welder is shipped with the engine and radiatorfilled with a 50% mixture of ethylene glycol and water.S e e t h e M A I N T E N A N C E s e c t...
Page 15 - CAUTION
A-5 INSTALLATION AIR VANTAGE® 500 (AU) A-5 The AIR VANTAGE® 500 (AU) is shipped with thenegative battery cable disconnected. Before you oper-ate the machine, make sure the Engine Switch is inthe OFF position and attach the disconnected cable securely to the negative (-) battery terminal. Remove the ...
Page 16 - REMOTE CONTROL
A-6 INSTALLATION AIR VANTAGE® 500 (AU) A-6 REMOTE CONTROL The AIR VANTAGE® 500 (AU) is equipped with a 6-pin and a 14-pin connector. The 6-pin connector is forconnecting the K857 or K857-1 Remote Control or forTIG welding, the K870 foot Amptrol or the K963-3hand Amptrol. When in the CC-STICK or CV-W...
Page 18 - • Shut the welder off.
A-8 INSTALLATION AIR VANTAGE® 500 (AU) A-8 CONNECTION OF AN NA-3 AUTOMATICWELDING SYSTEM TO THE AIR VAN-TAGE® 500 (AU) For connection diagrams and instructions for connect-ing an NA-3 Welding System to the AIR VANTAGE®500 (AU), refer to the NA-3 Welding System instruc-tion manual. The connection dia...
Page 19 - OPERATION; GENERAL DESCRIPTION; RECOMMENDED APPLICATIONS
b-1 OPERATION AIR VANTAGE® 500 (AU) b-1 SAFETY PRECAUTIONS Read and understand this entire section beforeoperating your AIR VANTAGE® 500 (AU). Do not attempt to use this equipment until you havethoroughly read the engine manufacturer’s manualsupplied with your welder. It includes importantsafety pre...
Page 20 - ENGINE CONTROLS; RUN STOP SWITCH; ENGINE TEMPERATURE GAUGE; CONTROLS AND SETTINGS
b-2 OPERATION b-2 ENGINE CONTROLS (Items 1 through 9) 1. RUN STOP SWITCH Toggling the switch to the RUN position energizesthe fuel solenoid for approximately 30 seconds.The engine must be started within that time or thefuel solenoid will deenergize, and the switch mustbe toggled to reset the timer. ...
Page 21 - OIL PRESSURE GAUGE; Idler Operational exceptions
b-3 OPERATION b-3 7. OIL PRESSURE GAUGE The gauge displays the engine oil pressure whenthe engine is running. 8. ENGINE PROTECTION The yellow engine protection light remains offwith proper oil pressure and under normal oper-ating temperatures. If the light turns on, theengine protection system will ...
Page 22 - • There is no VRD protection in the CV Mode.; AUXILIARY POWER CONTROLS
b-4 OPERATION b-4 13. WELD MODE SELECTOR SWITCH: (Provides 3 selectable welding modes) CV-WIRE CC-STICK TOUCH START TIG 14. ARC CONTROL: The ARC CONTROL WIRE/STICK knob is activein the WIRE and STICK modes, and has differentfunctions in these modes. This control is notactive in the TIG mode. CC-STIC...
Page 24 - WHAT ARE VRD AND ROCV DEVICES?
b-6 OPERATION b-6 WHAT ARE VRD AND ROCV DEVICES? VRD’s are gaining popularity as a “must have” safety accessory especially where welding applications arebeing carried out in an environment with a high-risk ofe l e c t r i c s h o c k s u c h a s w e t a r e a s a n d h o t h u m i dsweaty conditions...
Page 25 - STARTING TECHNIQUE
b-7 OPERATION b-7 Unlike other VRD’s Lincoln uses micro processor con- trol to monitor and establish the arc without the stick-ing and shorting of the electrode to the job as seen inmany other VRD installations. Due to the requirement of the resistance in the circuit to be low, for a VRD to operate,...
Page 26 - WELDER OPERATION; DUTY CYCLE
The AIR VANTAGE® 500 (AU) is equipped with therequired R.F. bypass circuitry for the connection ofhigh frequency generating equipment. The AIR VANTAGE® 500 (AU) and any high frequen-cy generating equipment must be properly grounded.See the K930-2 TIG Module operating manuals forcomplete instructions...
Page 27 - ARC GOUGING; Carbon Diameter; Table b.3 TYPICAL CURRENT RANGES
ARC GOUGING For optimal performance when arc gouging, set theAIR VANTAGE® 500 (AU) “WELD MODE” switch tothe “CC - STICK” position, and the “ARC CONTROL”to 10. Set the “OUTPUT” knob to adjust output current to thedesired level for the gouging electrode being usedaccording to the ratings in the follow...
Page 28 - PARALLELING; AUXILIARY POWER OPERATION; PLUS
PARALLELING When paralleling machines in order to combine theiroutputs, all units must be operated in the CC-STICKmode only at the same output settings. To achievethis, turn the WELD MODE switch to the CC-STICKposition. Operation in other modes may produce errat-ic outputs, and large output imbalanc...
Page 29 - TIG OPTIONS; ACCESSORIES
K2354-1 Air Dryer Kit-Minimizes water content in sup-ply air. Avoids cold weather air hose ice up. K2356-1 Control Panel Cover Kit-Clear plexiglasscover to protect control panel from dirt and debris, andto visually monitor machine operation. Lockable todeter vandalism. K2340-1 Lockable Fuel Cap / Fl...
Page 30 - MAINTENANCE; ROUTINE AND PERIODIC MAINTENANCE; WEEKLY; COMPRESSOR MAINTENANCE; ENGINE MAINTENANCE
D-1 MAINTENANCE D-1 AIR VANTAGE® 500 (AU) SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine or servicing the engine. • R e m o v e g u a r d s o n l y w h e n n e c e s s a r y t o perform maintenance an...
Page 31 - Clean Both Surfaces of the Outlet Tube; Caution; S e r v i c e I n s t r u c t i o n s; S i n g l e - a n d Tw o - S t a g e E n g i n e A i r C l e a n e r s
D-2 MAINTENANCE D-2 AIR VANTAGE® 500 (AU) Unfasten or unlatch the service cover. Because the filter fits tightly over the outlet tube to create the critical seal, there will be some initial resistance, similar to breaking the seal on a jar. Gently move the end of the filter back and forth to break t...
Page 33 - CHARGING THE bATTERY; Table D.1 Engine Maintenance Components
D-4 MAINTENANCE D-4 CHARGING THE bATTERY When you charge, jump, replace, or otherwise connectbattery cables to the battery, be sure the polarity iscorrect. Improper polarity can damage the chargingcircuit. The AIR VANTAGE® 500 (AU) positive (+) bat-tery terminal has a red terminal cover. If you need...
Page 34 - TROUbLESHOOTING; Local Lincoln Authorized Field Service Facility; HOW TO USE TROUbLESHOOTING GUIDE
E-1 TROUbLESHOOTING E-1 AIR VANTAGE® 500 (AU) If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubles...
Page 35 - PRObLEMS; C o n t a c t y o u r l o c a l L i n c o l n
E-2 TROUbLESHOOTING E-2 AIR VANTAGE® 500 (AU) Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubl...
Page 36 - Contact
E-3 TROUbLESHOOTING E-3 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance b...
Page 38 - WIRING DIAGRAM
F-1 WIRING DIAGRAM F-1 AIR VANTAGE® 500 (AU) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diag ram for a particular code is included with the machine. If the diagram is illegible, write to the Service Department for a replacem...
Page 39 - DIAGRAMS
Page 40 - IN; IN
F-3 DIAGRAMS F-3 AIR VANTAGE® 500 (AU) G N D 75 76 77 G R E E N K 29 1 O R K 40 4 75 IN P U T C A B LE 76 N .E . 77 K 77 5 O P TIO N A L R E M O TE C O N TR O L DA M AG ED . T HE EN GIN E G OV ER NO R S ET TIN G IS PR E-S ET AT TH E F AC TO RY - D O N OT AD JU ST AB OV E R PM SP EC IFIC AT IO NS LIS...
Page 50 - DIMENSION PRINT
F-13 DIMENSION PRINT F-13 AIR VANTAGE® 500 (AU) M 18 96 2-4 B TR A IL ER M O U N TIN G H O LE L O C A TIO N S . * 28 .9 9 73 6.3 19 .6 3 49 8.6 6.5 5 16 6.4 23 .6 9 60 1.7 50 .3 8 12 79 .7 54 .4 4 13 82 .8 14 .6 3 37 1.6 37 .3 0 94 7.4 45 .3 8 11 52 .7 31 .5 0 80 0.1 45 .6 7 11 60 2.2 4 56 .9 3.1 8 ...
Page 51 - NOTES